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ER-500
Programming Manual
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Badger Meter ER-500 Programming Manual

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ER-500 Advanced
DSY-PM-00028-EN-02 (February 2017)
Programming Manual
ER-500 Flow Monitor
Page ii February 2017DSY-PM-00028-EN-02
Programming Manual
CONTENTS
Scope of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operating The Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Menu Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Standard ER-500, Rate SU is Set to Simple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Advanced ER-500, Basic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Standard ER-500, Rate SU is Set to Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Advanced ER-500, Advanced Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
K-factors Explained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Modbus Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Modbus Register / Word Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Register Mappings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Control Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Page iii February 2017 DSY-PM-00028-EN-02
ER-500 Flow Monitor
Page iv February 2017DSY-PM-00028-EN-02

Scope of This Manual

SCOPE OF THIS MANUAL
This manual is intended to help you get the ER-500 flow monitor up and running quickly.
MPORTANTI
Read this manual carefully before attempting any installation or operation. Keep the manual accessible for future reference.

UNPACKING AND INSPECTION

Upon opening the shipping container, visually inspect the product and applicable accessories for any physical damage such as scratches, loose or broken parts, or any other sign of damage that may have occurred during shipment.
OTE:N If damage is found, request an inspection by the carrier’s agent within 48 hours of delivery and file a claim with the
carrier. A claim for equipment damage in transit is the sole responsibility of the purchaser.

SAFETY

Terminology and Symbols

Indicates a hazardous situation, which, if not avoided, is estimated to be capable of causing death or serious personal injury.
Indicates a hazardous situation, which, if not avoided, could result in severe personal injury or death.
Indicates a hazardous situation, which, if not avoided, is estimated to be capable of causing minor or moderate personal injury or damage to property.

Considerations

The installation of the ER-500 flow monitor must comply with all applicable federal, state, and local rules, regulations, and codes.
WARNING
EXPLOSION HAZARD - SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I, DIVISION 2.
AVERTISSMENT
RISQUE D’EXPLOSION - LA SUBSTITUTION DE COMPOSANTS PEUT RENDRE CEMATÉRIEL INACCCEPTABLE POUR LES EMPLACEMENTS DE CLASSE I, DIVISION 2.
WARNING
DO NOT CONNECT OR DISCONNECT EITHER POWER OR OUTPUTS UNLESS THE AREA IS KNOWN TO BE NON-HAZARDOUS.
AVERTISSMENT
RISQUE D’EXPLOSION. NE PAS DÉBRANCHER TANT QUE LE CIRCUIT EST SOUSTENSION, À MOINS QU’LL NE S’AGISSE D’UN EMPLACEMENT NON DANGEREUX.
MPORTANTI
Not following instructions properly may impair safety of equipment and/or personnel.

Electrical Symbols

Function Direct Current Alternating Current Earth (Ground) Protective Ground Chassis Ground
Symbol
DSY-PM-00028-EN-02 Page 5 February 2017

Introduction

INTRODUCTION
The ER-500 flow monitor incorporates state-of-the-art digital signal processing technology designed to provide the user with exceptional flexibility at a very affordable price. Though designed for use with Badger Meter® flow sensors, this monitor can be used with almost any flow sensor producing a low amplitude AC output or contact closure signal.
The ER-500 monitor uses contact closures from an ILR transmitter that translates to flow rate through the use of a scaling constant called a K-factor.
This monitor is also capable of accepting low-level frequency input signals typically found in flow sensors that generate a frequency output. The output signal for these type of sensors is a frequency proportional to the rate of flow. The ER-500 monitor uses the frequency information to calculate flow rate and total flow. If required, the flow monitor can easily be re-configured in the field.
J1
KB/Display
P2
+ –
RS485 Gnd
Setpoint 1
Setpoint 2
Iso Total Pluse
Total Reset
OC Total Pluse
Signal Gnd
Freq. In
4-20mA
TR_B
TR_A
Gnd
P1
2
1
+
–
+
–
+
–
JP1
Input Total Pulse Signal
Pulse
Mag
JP2
OC
Iso
JP3
High
Low
TB1
Figure 1: ER-500 monitor
The monitor is available in two different levels of functionality. The standard model provides all the functions necessary for the most common flow metering applications. The advanced version adds communications capabilities over an RS485 bus using Modbus RTU and control outputs.
DSY-PM-00028-EN-02Page 6 February 2017
(Should be set to Low for IOG Meter)
Auxiliary Reed

Installation

INSTALLATION

Connecting the ER-500 Monitor to a Pulse Output Device

The ER-500 monitor has two jumpers that are used to set the type of signal and the minimum amplitude of the signal that it accepts. When used with Badger Meter IOG oval gear meters, the Input Signal Level should be set to Low and the Input Waveform should be set for pulse as shown in Figure 2.
JP1
Pulse
Mag
OC
Iso
High
Low
Input Total Pulse Signal
Input Waveform Selection
(Should be set to Pulse for IOG meter)
JP2
JP3
Input Signal Level Selection
Figure 2: Input jumper settings
If the ER-500 monitor is a replacement, it must be calibrated for the IOG it is intended to be used with. The K-factor for the specific IOG meter must be programmed into the ER-500 monitor. The K-factor value is found on the calibration certificate that came with the IOG meter. For instructions on programming the K-factor, see Enter Flow Sensor's K-factor* on page 17.

Transmitter Connections

The ILR transmitter typically used with the IOG meter family has two sets of pulse output wires. The white and green output leads connected to the primary reed switch bank are generally the first choice (see Figure 3).
TR_B
RS485 Gnd
Setpoint 1
Setpoint 2
Iso Total Pluse
Total Reset
OC Total Pluse
Signal Gnd
TR_A
Freq. In
4-20mA
Reed Switch
Bank
Switch Bank
ILR
Pulse Transmitter
White
Green
Blue
Black
Figure 3: Typical IOG meter input connection
The ILR transmitter also has a secondary (auxiliary) set of pulse output wires. Either pair can be used to connect to the ER-500 monitor. The connections are:
P1
Gnd
Gnd
+
JP1
Input Total Pulse Signal
Pulse
–
Mag
+
JP2
–
OC
+
Iso
–
JP3
High
Low
TB1
Freq. In
+
–
Pulse
Mag
ILR Wires
ER-500 Terminals Reed Switch Bank (Primary) Reed Switch Bank (Auxiliary)
Freq. In + White Blue
Freq. In - Green Black
DSY-PM-00028-EN-02 Page 7 February 2017
10
Installation

Power Connections

The ER-500 monitor has two power supply options. The first power supply is an internal lithium 3.6V DC D size cell that powers the monitor for about six years when no outputs are used. The monitor can also be powered by a 4…20 mA current loop. See Figure 4. If the current loop is used, a sensing circuit within the monitor detects the presence of the current loop and automatically disconnects the battery from the circuit.
TR_B
Pulse
Mag
OC
Iso
High
Low
P1
JP1
Input Total Pulse Signal
JP2
JP3
…28V DC
4-20 mA
Current Loop
(10 …28V DC)
Load
RS485 Gnd
Setpoint 1
Setpoint 2
Freq. In
4-20mA
Iso Total Pluse
Total Reset
OC Total Pluse
Signal Gnd
TR_A
Gnd
+
–
+
–
+
–
TB1
Figure 4: Loop power connections
DSY-PM-00028-EN-02Page 8 February 2017

OPERATING THE MONITOR

Figure 5: Keypad detail

Buttons

MENU Switches between RUN and PROGRAMMING modes
Operating The Monitor
2
1
Scrolls backwards through the parameter options, increments numeric variables and scrolls backward through
UP
parameters
RIGHT
ENTER Saves programming information, advances to the next programming parameter, and used in the reset process
Scrolls forward through the parameter options, moves the active digit to the right and scrolls forward through parameters

Special Functions

MENU + ENTER Simultaneously press and hold to reset the current totalizer
MENU Press and hold for three seconds to enter Extended Programming mode
UP+ RIGHT Simultaneously press and hold to show the firmware version number, then the grand total

Modes

RUN Normal operating mode PROGRAM Used to program parameters in the display EXTENDED PROGRAMMING Used to program advanced variables into the display TEST Used as a diagnostic tool to show input frequency and totalizer counts
If the monitor is a replacement, the K-factor of the flow sensor has changed, or the monitor is being used with some other pulse generating device, programming is necessary.

Programming Using Frequency Output Flow Sensors

Each Badger Meter flow sensor is shipped with either a K-factor value or frequency data. If frequency data is provided, the data must be converted to a K-factor before programming the monitor. The K-factor represents the number of pulses per unit of volume. See Connecting the ER-500 Monitor to a Pulse Output Device on page 7. The K-factor is needed to program the monitor.
DSY-PM-00028-EN-02 Page 9 February 2017
Rate SU
(Rate Unit Setup)
Simple Advanced

Menu Structure

MENU STRUCTURE

Standard ER-500, Rate SU is Set to Simple

Shape Key
Basic Menu
Extended Menu
Sub Menu
START
KFacUnt
(K-Factor Unit)
Pul/Gal
Pul/m³ Pul/Ltr Pul/Ft³
=
Pulses/Gallon
=
Pulses/meter³
=
Pulses/Liter
=
Pulses/Ft³
KFactor
(K-Factor Value)
Numeric Entry
Flo Unt
(Rate/Total Units)
GPM
=
Gallons/Min
Gal
=
Gallons
OB/D
=
Oil Barrel/Day
BBL
=
Barrels
m³/D
=
Meters³/Day
m³
=
Meters³
m³/H
=
Meters³/Hour
m³
=
Meters³
LPM
=
Liters/Min
Ltr
=
Liters
PulsOut
(Pulse Output)
Disable
Enable
Fl=20mA
(Flow at 20 mA)
Numeric Entry
Clr G-T
(Clear Grand Total)
NO
YES
Passwd
(Password)
Numeric Entry
RstPswd
(Reset Password)
Numeric Entry
DSY-PM-00028-EN-02Page 10 February 2017

Advanced ER-500, Basic Menu

Menu Structure
Shape Key
Basic Menu
Extended Menu
Sub Menu
START
KFacUnt
(K-Factor Unit)
Pul/Gal
Pul/m³ Pul/Ltr Pul/Ft³
=
Pulses/Gallon
=
Pulses/meter³
=
Pulses/Liter
=
Pulses/Ft³
KFactor
(K-Factor Value)
Numeric Entry
RateInt
(Rate time interval)
=
Sec
Second
=
Min
Hour
Day
Minute
=
Hour
=
Day
RateUnt
(Unit/interval=T)
GPT
=
Gallons/T
LB/T
=
Liquor Barrel/T
OB/T
=
Oil Barrel/T
AF/T
=
Acre Feet/T
ML/T
=
Million Liters/T
LPT
=
Liters/T
m³/T
=
Meters³/T
Ft³/T
=
Feet³/T
MG/T
=
Million Gallons/T
MASS
Kg/T
=
Kilograms/T
Lb/T
=
Pounds/T
TotalUnt
(Totalizer Unit)
Gal
=
Gallons
LBL
=
Liquor Barrel
OBL
=
Oil Barrel
AFt
=
Acre Feet
MLt
=
Million Liters
LPT
=
Liters
m³
=
Meters³
Ft³
=
Feet³
MGa
=
Million Gallons
MASS
Kgs
=
Kilograms
Lbs
=
Pounds
TotlMult
(Totalizer Multiplier)
× 1000
×100
×10
0.1
0.01
1
=
× 100
=
× 10
=
× 1
=
× 0.1
=
× 0.01
=
×1000
Spec Gr
(Specic Gravity)
Numeric Entry
PulsOut
(Pulse Output)
Disable
Enable
Fl=20mA
(Flow at 20 mA)
Numeric Entry
Clr G-T
(Clear Grand Total)
NO
YES
Passwd
(Password)
Numeric Entry
Menu item appears
only when MASS
units are selected.
DSY-PM-00028-EN-02 Page 11 February 2017
RstPswd
(Reset Password)
Numeric Entry
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